Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel

In this study, the process of wire arc additive manufacturing (WAAM) by cold metal transfer (CMT) operation has been investigated for AISI 308L austenitic stainless steel. The wire feeder rate (WFR) was set between 3.5 and 7.0 m/min, while the current ranged from 72 to 115 A and the voltage from 11....

Full description

Bibliographic Details
Authors: Karamimoghadam, Mojtaba, Rezayat, Mohammad|||0000-0003-3929-2664, Contuzzi, Nicola, Denora, Vito, Mateo García, Antonio Manuel|||0000-0001-8336-6128, Casalino, Giuseppe
Format: article
Publication Date:2025
Country:España
Institution:Universitat Politècnica de Catalunya (UPC)
Repository:UPCommons. Portal del coneixement obert de la UPC
Language:English
OAI Identifier:oai:upcommons.upc.edu:2117/457452
Online Access:https://hdl.handle.net/2117/457452
https://dx.doi.org/10.1007/s43452-025-01274-8
Access Level:Embargoed access
Keyword:Additive manufacturing
Wire arc additive manufacturing
Process parameters
AISI 308L
Wire feeder rate
Àrees temàtiques de la UPC::Enginyeria dels materials
id ES_e82d752bca84f02a45af7b66dce8e3af
oai_identifier_str oai:upcommons.upc.edu:2117/457452
network_acronym_str ES
network_name_str España
repository_id_str
spelling Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steelKaramimoghadam, MojtabaRezayat, Mohammad|||0000-0003-3929-2664Contuzzi, NicolaDenora, VitoMateo García, Antonio Manuel|||0000-0001-8336-6128Casalino, GiuseppeAdditive manufacturingWire arc additive manufacturingProcess parametersAISI 308LWire feeder rateÀrees temàtiques de la UPC::Enginyeria dels materialsIn this study, the process of wire arc additive manufacturing (WAAM) by cold metal transfer (CMT) operation has been investigated for AISI 308L austenitic stainless steel. The wire feeder rate (WFR) was set between 3.5 and 7.0 m/min, while the current ranged from 72 to 115 A and the voltage from 11.1 to 12.6 V, as determined by the generator. Additionally, the robot speed was maintained at 7 mm/min for all samples. Microstructural and mechanical analyses have been conducted to improve the dilution area by considering having a different range of the width of the deposited part. Optical microscopy (OM) has been used for scanning the cross-section of the fabricated parts, and scanning electron microscopy (SEM), together with electron back scatter diffraction (EBSD), for monitoring the microstructure of the substrate, heat-affected zone (HAZ), and deposited metal. Energy-dispersive X-ray (EDX) analysis was applied to reveal the dilution area. Moreover, to link the oxidation of the peak deposition to the surface roughness, a focused ion beam (FIB) was used to remove a tiny volume of the peak surface. The results indicate that increasing the voltage and current in the WAAM process directly influences both microhardness and bead width. Microhardness reached up to 310 HV in the heat-affected zone (HAZ), while the width of the deposited bead increased from 2.9 mm at 799 W to 6.2 mm at 1449 W. Additionally, surface roughness along the deposited lines decreased with a higher wire feeder rate, with the lowest roughness recorded at 20.1 µm. Finally, FIB analysis revealed that the oxide layer was approximately 1 µm thick, with chromium penetration observed within the layer.This research was funded by Agency for Administration of University and Research (Agència de Gestió d’Ajuts Universitaris i de Recerca, AGAUR) (2021 SGR 01053), and CEX2023-001300-M project funded by MCIN/AEI/https:// doi.org/10.13039/501100011033.Peer ReviewedElsevier20252025-07-1520262026-03-1320262026-07-15journal articlehttp://purl.org/coar/resource_type/c_6501AMhttp://purl.org/coar/version/c_ab4af688f83e57aainfo:eu-repo/semantics/articleapplication/pdfhttps://hdl.handle.net/2117/457452https://dx.doi.org/10.1007/s43452-025-01274-8reponame:UPCommons. Portal del coneixement obert de la UPCinstname:Universitat Politècnica de Catalunya (UPC)Inglésengembargoed accesshttp://purl.org/coar/access_right/c_f1cfinfo:eu-repo/semantics/embargoedAccessoai:upcommons.upc.edu:2117/4574522026-05-27T15:37:01Z
dc.title.none.fl_str_mv Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
title Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
spellingShingle Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
Karamimoghadam, Mojtaba
Additive manufacturing
Wire arc additive manufacturing
Process parameters
AISI 308L
Wire feeder rate
Àrees temàtiques de la UPC::Enginyeria dels materials
title_short Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
title_full Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
title_fullStr Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
title_full_unstemmed Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
title_sort Impact of feed rate and arc power in wire arc additive manufacturing of AISI 308L stainless steel
dc.creator.none.fl_str_mv Karamimoghadam, Mojtaba
Rezayat, Mohammad|||0000-0003-3929-2664
Contuzzi, Nicola
Denora, Vito
Mateo García, Antonio Manuel|||0000-0001-8336-6128
Casalino, Giuseppe
author Karamimoghadam, Mojtaba
author_facet Karamimoghadam, Mojtaba
Rezayat, Mohammad|||0000-0003-3929-2664
Contuzzi, Nicola
Denora, Vito
Mateo García, Antonio Manuel|||0000-0001-8336-6128
Casalino, Giuseppe
author_role author
author2 Rezayat, Mohammad|||0000-0003-3929-2664
Contuzzi, Nicola
Denora, Vito
Mateo García, Antonio Manuel|||0000-0001-8336-6128
Casalino, Giuseppe
author2_role author
author
author
author
author
dc.subject.none.fl_str_mv Additive manufacturing
Wire arc additive manufacturing
Process parameters
AISI 308L
Wire feeder rate
Àrees temàtiques de la UPC::Enginyeria dels materials
topic Additive manufacturing
Wire arc additive manufacturing
Process parameters
AISI 308L
Wire feeder rate
Àrees temàtiques de la UPC::Enginyeria dels materials
description In this study, the process of wire arc additive manufacturing (WAAM) by cold metal transfer (CMT) operation has been investigated for AISI 308L austenitic stainless steel. The wire feeder rate (WFR) was set between 3.5 and 7.0 m/min, while the current ranged from 72 to 115 A and the voltage from 11.1 to 12.6 V, as determined by the generator. Additionally, the robot speed was maintained at 7 mm/min for all samples. Microstructural and mechanical analyses have been conducted to improve the dilution area by considering having a different range of the width of the deposited part. Optical microscopy (OM) has been used for scanning the cross-section of the fabricated parts, and scanning electron microscopy (SEM), together with electron back scatter diffraction (EBSD), for monitoring the microstructure of the substrate, heat-affected zone (HAZ), and deposited metal. Energy-dispersive X-ray (EDX) analysis was applied to reveal the dilution area. Moreover, to link the oxidation of the peak deposition to the surface roughness, a focused ion beam (FIB) was used to remove a tiny volume of the peak surface. The results indicate that increasing the voltage and current in the WAAM process directly influences both microhardness and bead width. Microhardness reached up to 310 HV in the heat-affected zone (HAZ), while the width of the deposited bead increased from 2.9 mm at 799 W to 6.2 mm at 1449 W. Additionally, surface roughness along the deposited lines decreased with a higher wire feeder rate, with the lowest roughness recorded at 20.1 µm. Finally, FIB analysis revealed that the oxide layer was approximately 1 µm thick, with chromium penetration observed within the layer.
publishDate 2025
dc.date.none.fl_str_mv 2025
2025-07-15
2026
2026-03-13
2026
2026-07-15
dc.type.none.fl_str_mv journal article
http://purl.org/coar/resource_type/c_6501
AM
http://purl.org/coar/version/c_ab4af688f83e57aa
dc.type.openaire.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv https://hdl.handle.net/2117/457452
https://dx.doi.org/10.1007/s43452-025-01274-8
url https://hdl.handle.net/2117/457452
https://dx.doi.org/10.1007/s43452-025-01274-8
dc.language.none.fl_str_mv Inglés
eng
language_invalid_str_mv Inglés
language eng
dc.rights.none.fl_str_mv embargoed access
http://purl.org/coar/access_right/c_f1cf
dc.rights.openaire.fl_str_mv info:eu-repo/semantics/embargoedAccess
rights_invalid_str_mv embargoed access
http://purl.org/coar/access_right/c_f1cf
eu_rights_str_mv embargoedAccess
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Elsevier
publisher.none.fl_str_mv Elsevier
dc.source.none.fl_str_mv reponame:UPCommons. Portal del coneixement obert de la UPC
instname:Universitat Politècnica de Catalunya (UPC)
instname_str Universitat Politècnica de Catalunya (UPC)
reponame_str UPCommons. Portal del coneixement obert de la UPC
collection UPCommons. Portal del coneixement obert de la UPC
repository.name.fl_str_mv
repository.mail.fl_str_mv
_version_ 1869422918963822592
score 15.811543

Similar Items